Method of making armature coils



- 1931- v. G. APPLE METHOD OF MAKING ARMATURE COILS 2 Sheets-Sheet Filed Oct //v VENTOR.

DEC. 8, 1931. v APPLE 1,834,925

METHOD OF MAKING ARMA'IURE COILS Filed Oct. 26, 1928 2 Sheets-Sheet 2 MYM Patented Dec. 8, 1931 UNITED STATES VINCENT G. APPLE, OF DAYTON, OHIO METHOD OF MAKING ARMATURE COILS Application filed October 26, 1928. Serial No. 315,341.

V coils suitable for radial entry into open core slots, the open ends of the-loops being somewhat prolonged and so located relative to the remainder of the bar that commutator segments may be composed of pairs thereof.

An object of the invention is to reduce the cost of an armature by eliminating the separately made commutator, thereby reducing the number of parts and the amount of labor and material required.

Another object is to improve the electric i5 circuit thru an armature by eliminating the units may be out from sheet stock.

Fig. 2 is a blank as it appears when out as in Fig. 1.

Fig. 3'is a cross section taken at 3-3 Fig. 2.

Fig. 4 is a cross section taken at 44 Fi 2.

Fig. 5 shows how blanks Fig. 2 are set.

Fig. 6 shows how blanks Fig. are folded.

Fig. 7 is an end View of Fig. 6.

Fig. 8 shows several loops Fig. 6 assembled in a core.

Fig. 9 shows a complete armature partly in section. I

Fig. 10 shows how the commutator lugs are formed when a conventional commutator binding means is employed.

Fig. 11 shows a conventional commutator binding means applied to loops made according to my invention.

Similar numerals refer to similar parts thruout the several views.

Heretofo're bar wound armatures of the open slot type have usually been made by pro viding loops of bar stock or wire and radially entering these loops into the open core slots, then providing a separate commutator and joining the open ends of the loops to bars of the commutator by soldering.

The volume of current carried by these bar windings is usually large and frequently the solder is melted and the usefulness ot'v the armature destroyed. This, together with the fact that the cost of separately producing a conventional commutator is considerable, and the labor incident to joining the loop ends to the commutator bars is costly, makes the hereinafter described method 01 great value both as to cost and dependability.

A segment of a commutator is preferablyof Wedge shaped'cross section, but where a core having rectangular winding apertures is to be employed the conductor bars are preferably of rectangular cross section.

The method of procedure hereinafter set forth provides anintegral winding loop coinprising conductor bars of rectangular cross section and commutator segments of wedge shaped cross section with minimum labor and minimum waste of material.

To carry out my method, sheet stock, preferably copper or other good conductive material,is passed thru a punch press or similar machine and cut apart on the lines 15, 15 etc., Fig. 1. At each stroke of the press two snitably shaped punches strike spot 17 of the sheet. The ends of these punches are beveled where they meet the sheet so that spots 17 are struck harder and made thinner at the edge 18 than at the edge 19.

' The striking punches act ahead of the cutting punches so that when a blank comes under the cutting punch it already has the two beveled spots formed therein.

From a consideration of Fig. 1 it will be apparent that blanks Fig. 2 may be cut from a sheet, one after the other with very little waste, and that when they are out they will comprise a long conductor bar 16 of rectan gular cross section as at 13 Fig. 8 having lugs 24 and 25 of a wedge shaped cross section 14 Fig. 4 at each end and notches 26 and 27 cut in the ends of the lugs.

The structure Fig. 2 is next offset by bending the conductor bar 16 at 30. This pro vides a conductor bar 22 adapted to occupy a position in the outer layer of the winding and a conductor bar 23 adapted to occupy a position in the inner layer of the winding.

The structure Fig. 5 is now folded to compose the loop shown in the plan view Fig. 6 and end View Fig. 7, Where bars 22 and 23 are axially parallel and circumterentially spaced apart but radially at variance, while lugs 24 and 25 are displaced to other axially parallel positions circumferentially spaced 7 apart fiuom the conductors but radially-equidistant from the armature axis. The lugs 24 and 25 are of such thickness as to together compose a commutator segment e Segments of conventional commutators are frequently composed of several oircu-m -terentially adjacent layers, soalso in the present invention a lug 24 and a'lug'25' areplaced circumferentially ad acentv in electrical contact and held by a commutator segment v binding; means which. impinges on notchesQG andQL rig, 8" shows several loops '6 in place inacore.53.v The purpose of this figure isto show .how a continuous circuit is. provided by placing a commutator lug Qtfcircum terentia-lly tad iacentt'of a commutator lug25, two such lugs in electrical contact joining ad3acent loops ofthe circuit and togethercomposing one commutator segment. 4 e

Other requirements of common practice must, be ,met, such as :having, the core slots lined. with insulating material keepingthe outer and inner layers of the winding electricallyseparated, etc.

WhenQa number.oflloopsequahtoithe numoffjslotsvhave been assembled in a core,

pairs,otcommutatorlugs must be held: .in in-v timate electrical contact, one member ofa pair with the other, tocomposecommutator segments and the segments must be mechan bound togetl1er,..tho electr cally, separated fromeach other, to compose acommutatoru I Spacers 3,4 of insulating material maybe insertedwto separate the several segments but must notybeplaced between two lugs which together compose .a segment Spacers, 34L may, however, be eliminated by 'PQTlHlttHlg insulation to extend between the segments when. the commutator binding means is bes-ap a i r [A preferred-binding means s. shown in 9 where molded insulating material-31L surrounds the conductor barsand impinges on-the matches-.26 and '27 to bindvthe commutater segments together. Any suitable insulatingi-material may be used, ;as may :anv

suit-able mold, .-a requirement being that :the

commutator lugszbe subjected to iu-warduadiall pressure, ort-ha't th ey may be otherwise held to keep them inintimate "contact -while molding is taking place, ai'idw-hi l'e the drawing shows the entire-winding covered with insulating marines economy. mayjbe effec'ted'by so arranging the mold. as to per mit insulating material 1130 surround the commuta'tor end of the armature only, and when vnotched:asat 39rand 40. In Fig. 11 a nut 41 draws together the beveled head 42 of sleeve 43 and the beveled washer 445 against msulation 45, after the manner practiced in build ing ordinary commuta-tors.

While in the foregomg I haveshown and described" a .methodofprocedure consisting ofa number of steps taken in a given order,

it is to be understood thatthese steps need not-be taken in the ordergivein nor do they needutoxbe taken one at a time as ndicated.

For instance a pluralitysofspots 17 maybe struck at, one time and a plurality of blanks Fig.2 maybe cutat one stroke of the press,

andwhile striking thespOts preferably precedesthe cutting ofthe blanks the reverse order .may berifollowed, if-desired, or in an armature having a largenumber ofcommutatordivisions, making the sideof its segments-substantially parallel, the striking operation may be omitted entirely if desired.

The :ofi'setting ofthe blanks as iuFig. 5,-

however, necessarily follows thev cutting, since blankscut as in Fig. 5 could not be taken from a sheet consecutively without waste, and this :part of the procedure .constitutes one ofthe salient features of the invention.

Having described my invention, 1 claim v1. The method of making an integral winding loop comprising two parallel's paced apart conductor barsjoinedtogether at one endfland terminating at the open ends in commutator lugs, which consists of providing a sheet of conductive material, cutting blanks having .two conductor; bars together and n -alignment, with wider commutator lugs at the ends extending oppositely and out of alignmenhfoffsetting the blan'k edgewise at its middle part to bring the .twocom ductor bars onto-f alignment and the lugs into-alignment, then folding the blank to compose a loop in the manner disclosed.

2. The method of making an integral windingloop-comprisingrtwo parallel spaced apart conductor bars of rectangular cross section joined together at one cndandterminating in commutatorlugs at the open ends, which consists of providing asheet of conductive material ofiuniiorm thickness, w

cutting blanks having two conductor bars together and an alignment with wider commutator lugs at the ends extending oppositety and out ofal-ignment, offsetting the blankedgew'ise at its middle part :to bring .the two conductor bars out of alignment and the lugs into alignment, then folding the blank to compose a loop in the manner disclosed.

3. The method of making an integral winding loop comprising two parallel spaced apart conductor bars of rectangular cross section joined together at one end and terminating at the open ends in wedge shaped commutator lugs, which consists of providing a sheet of conductive material of uniform thickness thruout, striking portions of the sheet to produce areas which are thicker at one edge than at the other, cutting blanks having two conductor bars together and in alignment, with wider commutator lugs at the ends taken from the said areas and extending oppositely and out of alignment, olfsetting the blank edgewise at its middle part to bring the two conductor bars out of alignment and the two lugs into alignment, then folding the blank to compose a loop in the manner disclosed.

4:. The method of making an integral armature winding unit comprising a turn of the L winding and two commutator lugs from fiat sheet stock, which consists of cutting blanks having two conductor bars together and in alignment with Wider commutator lugs at the ends extending oppositely and out of alignment, off-setting the blank edgewise at its middle part to bring the two conductor bars out of alignment and the two lugs into alignment, folding the blanks sidewise to bring the two offset conductor bars into parallel spaced apart positions and the two aligned commutator lugs into other parallel spaced apart positions.

5. The method of making an integral winding loop comprising two parallel spaced apart conductor bars joined together at one end and terminating at the open ends in commutator lugs, which consists of providing a sheet of conductive material, cutting blanks having two conductor. bars together and in alignment, with wider commutator lugs at the ends extending oppositely and out of alignment, folding and curving the blank with reference to an axis, bringing the two offset, bars into axially parallel angularly spaced apart positions the one bar farther from the said axis than the other bar, and the two aligned lugs into different axially parallel angularly spaced apart positions, both lugs at equal distances from the said axis.

6. The method of making an integral winding loop comprising two parallel spaced apart conductor bars joined together at one end and terminating at the open ends in commutator lugs, which consists of providing a sheet of conductive material, cutting blanks having two conductor bars together and in alignment, with wider commutator lugs at the ends extending oppositely and out of alignment, folding and curving the blank my name.

VINCENT G. APPLE. 

